Key cutting machine

ABSTRACT

A key cutting machine is provided for cutting a key blank from a master key. The key cutting machine comprises a first cutting member that rotates about a substantially horizontal axis for cutting a key pattern on a key blank and a second cutting member that rotates about a substantially vertical axis for cutting a key pattern on a key blank. Additional improvements or features of a key cutting machine are also described.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. application Ser. No.11/709,668, filed Feb. 22, 2007 now U.S. Pat. No. 7,387,476, whichclaims the benefit of U.S. Provisional Patent Application Ser. No.60/775,476, filed on Feb. 22, 2006, which are hereby incorporated intheir entirety by reference.

FIELD OF THE INVENTION

The present invention generally relates to a key cutting machine, andparticularly, to a key cutting machine that is capable of cutting astandard key and a sidewinder key.

BACKGROUND OF THE INVENTION

There are several types of key cutting machines used in the industry.Generally, these key cutting machines cut only one type of key known inthe field. For example, conventional key cutters use a cutting member,such as, a circular rotating saw-like blade to cut a key pattern in theblade of a standard key blank. These cutting machines generally includea pair of vise grips or clamps mounted on a carriage. A master keyhaving a key pattern previously cut therein is placed in one clamp and akey blank is placed in the adjacent vise clamp. The key pattern of themaster key faces a stylus or tracer bar on the key cutting machine andthe key blank faces a cutting wheel. The carriage is pivotally andlinearly movable along a longitudinal supporting shaft and presses thekey pattern of the master key against the tracer bar. Simultaneously,the carriage presses the key blank against the cutting wheel. Thecarriage is then shifted longitudinally along the supporting shaftthereby causing the key pattern on the master key to travel on thetracer bar and impart corresponding pivotal movement to the carriage sothat the cutting wheel cuts the identical key pattern into thecorresponding key blank. The key blank cut with the master key patternis then removed from the vise or grip and buffed on a buffing wheel toremove any burrs.

These types of key cutting machines are the most prevalent cuttingmachines in the industry. However, these devices are only capable ofcutting standard keys. As a result, these devices cannot cut other typesof keys known in the field. For example, high security side milled keys,or sidewinder keys, are often used in the automotive sector. Sidewinderkeys typically include a shaped head portion and a flat shaft portionextending from the head portion. The flat shaft portion is oftenreferred to as the “blade”. The blade has two opposite major surfacesthat are each cut by milling so as to cause the surfaces to correspondto a specific bit notch pattern, or ciphering. A drill bit-like cuttingmember is required to cut such keys. The master key can include holes,dimples, or a sidewinder cut that can be duplicated. The key is tracedand the drill bit-like cutting member moves to shape the key.

To accurately duplicate the various keys known in the art, facilitiesmust purchase multiple key cutting machines. By having only one type ofkey cutting machine, facilities cannot accurately reproduce other typesof keys. Therefore, there is a need in the field to provide a keycutting machine that is capable of cutting more than one type of key ina single machine. The dual functionality would increase versatilitywhile eliminating the need for multiple key cutting machines.

Another deficiency of key cutting and duplicating machines is that thecutting tool is typically driven through an intermediate belt and pulleyassembly by the output shaft of a driving motor. This increases not onlythe number of the parts, but also the transmission friction loss.

Yet another deficiency of key cutting and duplicating machines is that aspring biased carriage system is utilized that can cause the clampmembers and carriage to prematurely disengage during the final cuttingportion of the key tip. Therefore, the cutting wheel tends to slide offof the end of the key blank and therefore not complete the key pattern.

Presently, there is no known key cutting machine or method that avoidsthe problems associated with the known devices listed above. The presentinvention as described and claimed herein, addresses the deficiencies ofprior art key cutting machines. Nothing in this description should limitthe scope of the invention beyond the scope claimed.

SUMMARY OF THE INVENTION

The present invention pertains to a key cutting machine for cutting akey blank from a master key. In one embodiment, a key cutting machinemay comprise a first cutting member rotatable about a substantiallyhorizontal axis and a second cutting member rotatable about asubstantially vertical axis.

In an embodiment, a key cutting machine has a moveable carriage and aninterchangeable clamp structure. In yet another embodiment, a keycutting machine has a first cutting member that rotates about asubstantially horizontal axis for cutting a first key pattern on a firstkey blank, and a second cutting member rotatable about a substantiallyvertical axis, that is pivotable from a key cutting position to astorage position.

DESCRIPTION OF THE DRAWINGS

Operation of the invention may be better understood by reference to thefollowing detailed description taken in connection with the followingillustrations, wherein:

FIG. 1 is perspective view of a first embodiment of an interchangeablekey cutting machine.

FIG. 2 is an exploded view of the key cutting machine of FIG. 1preparing for interchanging to a sidewinder key cutting machine.

FIG. 3 is an exploded view of the key cutting machine of FIG. 1preparing for interchanging to a sidewinder key cutting machine.

FIG. 4 is an exploded view of the key cutting machine of FIG. 1preparing for interchanging to a sidewinder key cutting machine.

FIG. 5 is a side view of the key cutting machine of FIG. 1.

FIG. 6 is a perspective view of the key cutting machine of FIG. 1 withthe sidewinder key cutting apparatus connected thereto.

FIG. 7 is a front view of the key cutting machine of FIG. 1 with thesidewinder key cutting apparatus connected thereto.

FIG. 8 is a rear view of the key cutting machine of FIG. 1 with thesidewinder key cutting apparatus connected thereto.

FIG. 9 is a front view of the key cutting machine of FIG. 1 with thesidewinder key cutting apparatus and housing connected thereto.

FIG. 10 is a side view of a key blank.

FIG. 11 is a side view of a master key.

DETAILED DESCRIPTION

While the present invention is described with reference to embodimentsdescribed herein, it should be clear that the present invention is notlimited to such embodiments. Therefore, the description of theembodiments herein is merely illustrative of the present invention andwill not limit the scope of the invention as claimed.

With reference to FIGS. 10 and 11, a brief introduction to key blanksand master keys is as follows. A key blank 100 generally comprises ahead 102, a shoulder 104, and a blade 106. Key blanks can also beprovided with keyway grooves 108 which are long, narrow, milled-outareas along the sides of the blade 106 that allow the blade 106 tobypass the wards in the keyway. Such keyway grooves 108 may previouslybe cut into a key blank so as to simplify the key cutting operation.Therefore, when duplicating a master key, a key blank 100 must beidentified as either identical to or similar to the master key. The keyblank 100 is cut from a master key 110. The master key 110 generallycomprises a head 102, a shoulder 104, a blade 106, and a keyway groove108. However, the master key 110 has a key pattern 112 already cut intothe blade 106. The particular key pattern 112 corresponds to the pin andtumbler design of a lock. In another embodiment, the key blank 100 maybe a key blank for a sidewinder key, and the master key 110 may have asidewinder key pattern 112 already cut into the blade 106. FIGS. 10 and11 illustrate a conventional master key 110 and key blank 100. Inanother embodiment, master key 110 may be a sidewinder master key with asidewinder pattern 112, and blank key 100 may be a sidewinder blank key.

With reference to FIGS. 1 and 2, a brief description of the structure ofthe key cutting machine 10 of the present invention is as follows.Exploded views showing the parts and assembly of the key cutting machine10 are shown in FIGS. 2-4. An assembled key cutting machine of thepresent invention is shown in FIG. 1. The key cutting machine 10 mayhave a base 2, a cutting member 4, a motor 6 and a wire brush 8. The keycutting machine has a pair of vise grips or clamps 12, having top jaws14 and bottom jaws 16, mounted in a corresponding groove of the carriage18. An actuating handle 20 selectively locks the clamp 12 in a fixedposition. Therefore, the arrangement allows clamps 12 to be easilyremoved, replaced, and/or positioned.

A spare key holder 21 may be connected to the carriage 18. A master key110 having a key pattern 112 previously cut therein is placed within theleft-most clamp 12 on the carriage 18 and a key blank 100 forduplicating the keyway groove 108 of the master key 112 is placed in theadjacent clamp 12 on the carriage 18. A gauge fork 26 may be mounted onthe base 2. The gauge fork 26 may be used to align the master key 110and the key blank 100 in the correct and exact orientation within theclamps 12. The carriage 18 is moveable longitudinally with respect tothe cutting wheel 4. The carriage 18 may be moveable toward and awayfrom the cutting wheel 4. The motor 6 may be turned on manually, or aswitch can automatically engage the motor when the carriage 18 is movedtoward the cutting wheel 4. The key cutting machine 10 has a stylus ortracer 22 that faces the key pattern 112 of the mounted master key 110.The cutting wheel 4 faces the mounted key blank 100. To cut the pattern112 from the master key 110 into the key blade 106 of the key blank 100,the master key 110 may be manually or automatically pressed against thetracer 22. The key blank 100 is likewise pressed against the cuttingwheel 4 to the same depth as permitted by the tracer 22 against themaster key 110. The carriage may be moved longitudinally, with respectto the cutting wheel, to cut the key pattern 112 from the master key 110into the key blade 106 of the key blank 100.

A feature of the key cutting machine 10 of the present invention is theuse of an improved carriage 18 versus the old tilt carriage of the priorart. The carriage 18 promotes key cutting accuracy as well asinterchangeability of clamp types. As shown in FIG. 1, the carriage 18can be driven by lever 52 so that the carriage 18 can movelongitudinally as well as toward and away from cutting members. Thecarriage allows for a straight line, coplanar approach to the cuttingwheel 4, as opposed to the conventional tilt/pivot approach. As shown inthe exploded FIGS. 2-4, the carriage 18 is slidably mounted over a shaftguide 30 with four cylindrical apertures 32, 34. An upper shaft pair 36,lower shaft pair 38, and corresponding bearings (40 and 42,respectively) are positioned in the shaft guide apertures 32, 34 so thatthe shafts are axially moveable. The shaft pairs 36, 38 may bepositioned perpendicularly with respect to each other. This, allows thecarriage 18 to move longitudinally and towards and away from the cuttingwheel 4 in a substantially horizontal plane relative to the base 2.

As shown in FIG. 5, upper shaft pair 36 allows carriage 18 to movetoward and away from the cutting wheel 4. Each upper shaft 36 is mountedto opposing ends of the carriage 18. When mounted, the upper shaft pair36 is positioned above the base 2. The carriage 18 can be secured withrespect to movement toward and away from the cutting wheel 4 by rotatinga set screw 48 to lock the carriage 18 against the upper surface of theshaft guide 30. Longitudinal movement of the carriage 18 is accomplishedby the lower shaft pair 38. The lower shaft pair 38 is positioned in theshaft guide 30 below the base 2 surface. The lower shaft pair 38 ismounted to a plate 50, as well as the bottom of the base 2, best shownin FIG. 2. Movement of the carriage 18 is controlled by lever 52. Lever52 is connected to the carriage 18 by a knuckle bearing 54. It isunderstood that the distance between the lever 52 and carriage 18 can beadjusted to increase or decrease travel.

The key cutting machine 10 may be operated in an automatic mode ormanual mode. To operate the key cutting machine 10 manually, the masterkey 110 and the key blank 100 are placed in the appropriate jaws 12. Thegauge fork 26 is used to verify the proper position and alignment of themaster key 110 and key blank 100 and then rotated away from the clamp toan out of the way position, as shown in FIG. 1. The carriage 18 may thenbe positioned with the lever 52 so that tracer 22 engages the master key110 adjacent the head 102. The carriage 18 is moved longitudinally tothe left, and held against the tracer and cutting member by the user viathe lever 52. The tracer 22 engages the pattern 112 in the master key110 and the cutting wheel 4 cuts the identical pattern into the keyblank 100. The user can move the carriage 18 at will longitudinally andthe master, key pattern 112 is cut into the key blank 100. When thecutting process is complete, the user can lower, or release the lever 52so that the carriage 18 slides away from the cutting wheel 4 to a“carriage down” position at the lower end of the base, as shown in FIG.3. It is understood that during the fall to the carriage down position,a switch (not shown) can automatically turn the motor 6 off. The keyblank 100 is then removed from the clamps 12 and buffed in the wirebrush 8.

In one embodiment, to ensure that the key blank 100 and the master key110 are positioned properly within the key cutting machine 10, the keycutting machine 10 may include an additional feature wherein the clamps12 are selectable for properly clamping and holding numerous types ofkeys therein. In particular, the upper and lower jaws 14, 16 may berotatable to provide separate clamping areas therebetween to accommodatedifferent types of master keys and key blanks for accommodating keywidth and particular groove structures. Therefore, depending upon thetype of master key and key blank being used, the clamps 12 of the keycutting machine 10 may be rotated to accommodate particular keyconfigurations. Such jaw positions can be color coded or identified toassist the operator in identifying the proper jaws to use withparticular master key and key blank configurations. The improvedcarriage 18 also ensures proper positioning and allows for interchangingclamps for different cutting machines, so that only one carriage may beused. Illustrative examples of keys that can be held for duplicationinclude conventional, tubular, dimpled, and sidewinder cut keys. This isparticularly useful when a second cutting assembly is mounted on thebase 2, as described below.

In yet another feature, the position of a guard 55 covering the brushcan be adjusted by loosening screw 57, thereby allowing the user to buffa newly cut key at any desired position. Further, the key cuttingmachine can utilize a direct drive motor 6. Conventional key cuttingmachines utilize a pulley motor system. By utilizing a direct drivemotor 6, the motor performance can be greatly improved and the size andpower supply requirements can be reduced. Thus, power efficiency andimproved performance can be achieved.

Another feature or improvement of the key cutting machine 10 of thepresent invention is that the cutting machine can utilize a cam drive toautomatically drive the carriage 18 during conventional key cutting.Other key cutting machines utilize a spring biased carriage system. Adeficiency of spring biased carriage system is that the spring biasedcarriage system may not securely position the clamp members and carriagethrough the final cutting portion of the key tip. Therefore, the cuttingwheel may slide off of the end of the key blank and not complete the keypattern. Utilizing a cam drive enables the cutting wheel 4 to drivethrough the end of the key and prevents the carriage 18 from backing offthe tip of the cut key.

Another improvement of the present invention is a novel assembly whereina second vertical cutting member can be mounted with a first horizontalcutting member to the same base 2 on the key cutting machine 10. In apreferred embodiment, the second cutting member is a sidewinder cuttingassembly 70 with a sidewinder drill-bit type cutting member so thatdimples, holes, or contour cutting can be provided. It is understoodthat the sidewinder cutter assembly 70 can be fixedly, or removeably,mounted to the base. As shown in FIGS. 6-8, a sidewinder cutter assembly70 can be mounted to the base 2 and plugged into a power supply outlet(not shown). As shown in FIG. 7, the sidewinder cutting assembly 70 ofthe illustrated embodiment comprises a cutter 126 and tracer 128substantially vertically disposed above the base 2, and a support/frame76. The sidewinder cutter 126 is generally a drill-type cutting memberso that dimples, holes, or contour cuts can be made.

As shown best in exploded FIGS. 2-4, the base 2 can have an opening, orkeyway 80, for removably attaching the sidewinder cutting assembly 70.The sidewinder cutting assembly 70 can be mounted so that a key nut 82is positioned within the keyway 80, the sides sliding under the base 2.Plate 84 is mounted on the top of the base 2. As shown in FIGS. 3 and 4,a recess 83 may be provided in base 2 to facilitate positioning of plate84 on the base 2. When placed in the desired position the sidewindercutting assembly is secured by rotating the locking nut lever 86clockwise ¼ of a turn. The threaded rod 88 rotates and pulls key nut 82toward the bottom of the base 2, thereby securing the sidewinder cuttingassembly 70 to the base 2.

In another embodiment, the sidewinder cutting assembly 70 may bepivotally mounted between a key cutting position and a storage position.The ability to pivotally move the sidewinder cutting assembly 70 allowsunimpeded use of the cutting wheel 4 without having to remove thesidewinder cutting assembly 70. As best shown in exploded FIGS. 2-4,column 90 includes a bearing 92 (at 93) and bushing 94. To rotate theassembly, the lock nut lever 86 is loosened, for example, rotating orturning the lock nut lever 86. The lock positioner 96 may then be liftedout of the aperture 98 of the plate 84. The sidewinder cutting assembly70 may be pivoted to a desired position wherein the lock positioner 96will slide into position in the desired aperture 98 of the plate 84. Thelock nut lever 86 is rotatable to a tightened position. It is understoodthat the plate 84 can have any number of holes to position thesidewinder assembly 70 at any desired position. It is also understoodthat even if the sidewinder assembly 70 is permanently attached to thecutter, it may still have the pivotable capability.

As shown in FIGS. 6 and 7, a cutter housing 120 and a tracer housing 122are mounted on a plate 124. The cutter housing 120 and tracer housing122 hold the sidewinder cutter 126 and tracer 128, respectively. Thecutter 126 and tracer 128 are removably secured in place by a set screw,thereby allowing use of different cutters and tracers. It is understoodthat the cutter 126 and corresponding tracer 128 may be removablysecured in any manner as will be appreciated by one of ordinary skill inthe art. An electric motor 130 is mounted to plate 124 and connected tothe cutter 126 and drives the cutter 126 in a direct drive manner. Whennot in use, the cutter 126 and tracer 128 are held in an unactuatedposition by springs 136, shown in FIGS. 2-4. Lever 132 is selectivelymanually rotatable for vertically lowering along guides 134 the cutter126 and tracer 128 to engage the blank key and master key, respectively,in a manner that may be similar to a conventional drill press. Thecutter 126 and tracer 128 can be positioned at any location on theguides 134 by rotating lock handle 138 to cause block members 140 tosecurely engage the guides 134.

In one illustrative embodiment, to use the sidewinder cutting assembly70, the clamp 12 may be removed from the carriage 18, and replaced witha sidewinder clamp 142 capable of holding the master key 110 and the keyblank 100. The sidewinder clamp 142 is best shown in FIG. 6. Thesidewinder clamp 142 is positioned in a corresponding groove 15 of thecarriage 18. As shown in FIGS. 2-4, the interchangeable conventionalclamps 12 and the sidewinder clamps 142 may have protrusions 13 and 143,respectively, for positioning in the groove 15. An actuating handle 20selectively locks the sidewinder clamp 142 in a fixed position on thecarriage 18. (Actuating handle not shown in FIG. 6). The arrangement ofthe clamp 142 and carriage 18 allows the clamp 142 to be easily removed,replaced, and/or positioned. The carriage 18 may then be selectivelymanually positioned so that the cutter 126 and the tracer 128 arevertically aligned with the key blank 100 and master key 110,respectively. Next, the tracer depth is set. To set the depth, the lockhandle 144 may be loosened. Next, the cutter positioning arm 132 may berotated to lower the tracer 128 to the master key 110 to set the tracer128 to the cutter depth. When set, the tracer lock handle 144 may betightened to secure the tracer 128 at the desired depth. Next, thecutter positioning arm 132 is released allowing the cutter 126 and thetracer 128 to return to its unactuated position. The cutter positioningarm 132 lowers the tracer 128 and cutter 126, triggering a second switch(not shown) and energizing the cutter 126. The lock handle 138 istightened to secure the cutter 126 and tracer 128 in position. Thecarriage 18 is then engaged with the tracer 128 which follows thecontour of the master key 110. This can be repeated for the other sideof the key blank 100, if necessary.

A guard 150 is provided for operator safety. As shown in FIG. 6, theguard 150 can surround the cutter 126 and the tracer 128. As will beappreciated and understood by those skilled in the art, the guard 150can optionally be connected to a vacuum device (not shown). Additionalhousing may be used to prevent accidental contact with any moving parts,as best shown in FIG. 9. A vacuum system can be mounted on or near thekey cutting machine 10 and plugged into a power supply outlet, on ornear the key cutting machine (as described in U.S. patent applicationSer. No. 10/970,844, filed on Jun. 23, 2005, and related provisionalapplication No. 60/512,636, filed on Oct. 20, 2004, herein incorporatedby reference herein). A vacuum port may be located within the housing soas to provide vacuum communication between the interior of the housingand the vacuum system. In one embodiment, a vacuum line may run from theport to the base 2 at aperture 200. The port may be located directlyunder the cutting wheel 4. The vacuum tube may be removably connected tothe vacuum port so that when the vacuum tube is connected to the vacuumport, the vacuum is capable of collecting key shavings from within thehousing created during a key cutting operation. When the vacuum tube isdisconnected from the vacuum port, the vacuum tube can be used as ahand-held vacuum wand to vacuum metal shavings from the key cutting areaand surrounding area for general clean-up. Preferably, the vacuum isactuated when the cutting wheel is actuated.

The invention has been described above and, obviously, modifications andalternations will occur to others upon a reading and understanding ofthis specification. The claims as follows are intended to include allmodifications and alterations insofar as they come within the scope ofthe claims or the equivalent thereof.

1. A key cutting machine comprising: a base member; a first cuttingmember positioned on said base member, said first cutting member havinga cutting wheel; a second cutting member positioned on said base member,said second cutting member capable of cutting a sidewinder key patternonto a key blank; a carriage connected to said base; a first key clampconnected to said carriage and moveable therewith; a lever connected tosaid carriage, wherein said lever is capable of driving movement of saidcarriage; and wherein said carriage is manually movable within a planerelative to said base.
 2. The key cutting machine of claim 1 whereinsaid first cutting member is rotatable about an axis substantiallyparallel to said base member.
 3. The key cutting machine of claim 2wherein said second cutting member is rotatable about an axissubstantially perpendicular to said base member.
 4. The key cuttingmachine of claim 1 wherein said first and second cutting members arefixedly mounted to said base member.
 5. The key cutting machine of claim1 wherein said second cutting member is a drill-type cutting member. 6.The key cutting machine of claim 1 further comprising a first tracingmember connected to said base member and capable of tracing a keypattern from said master key.
 7. The key cutting machine of claim 6further comprising a second tracing member connected to said base memberand capable of tracing a sidewinder key pattern from said master key. 8.The key cutting machine of claim 1 wherein said carriage is slidablyconnected to said base member.
 9. The key cutting machine of claim 8wherein said carriage is capable of moving along two substantiallyperpendicular axes.
 10. The key cutting machine of claim 9 wherein saidtwo perpendicular axes are substantially parallel to said base member.11. The key cutting machine of claim 1 further comprising a second keyclamp connected to said carriage.
 12. A key cutting machine comprising:a base member; a first cutting member connected to said base member andcapable of cutting a key pattern onto a key blank, wherein said firstcutting member is rotatable about an axis parallel to said base member;a second cutting member connected to said base member and capable ofcutting a sidewinder key pattern onto a key blank, wherein said secondcutting member is rotatable about an axis perpendicular to said basemember; a carriage movably secured to said base member; a leverconnected to said carriage; a key clamp connected to said carriage;wherein said carriage is movable relative to said base along a firstaxis and a second axis that intersects said first axis.
 13. The keycutting machine of claim 12 wherein said second cutting member isremovably connected to said base member.
 14. The key cutting machine ofclaim 12 wherein said first axis and said second axis are parallel tosaid base.
 15. The key cutting machine of claim 14 wherein said keyclamp is removably connected to said carriage.
 16. The key cuttingmachine of claim 12 further comprising a second key clamp removablyconnected to said carriage.
 17. The key cutting machine of claim 12wherein said second cutting member is rotatably connected to said base.18. The key cutting machine of claim 17 wherein said second cuttingmember is rotatable between a cutting position and a storage position.